Controller, forming machine, and control method

ABSTRACT

A controller controls operation of a forming machine capable of forming a workpiece. The controller includes: an object determination unit configured to determine an object other than the workpiece and the forming machine based on image data sensed by a sensor; a setting unit configured to set a plurality of determination areas based on a bolster shape of the forming machine included in the image data; a detection unit configured to detect entry of the object into each of the plurality of determination areas set by the setting unit; and a control unit configured to limit operation speed of the forming machine based on the determination area in which the entry of the object has been detected by the detection unit.

BACKGROUND OF THE INVENTION Field of the Invention

The present disclosure relates to a controller for controlling operationof a forming machine, the forming machine including the controller, anda method for controlling the forming machine.

Description of the Background Art

Forming machines such as press machines and press brakes have beenconventionally known.

Japanese Patent Laying-Open No. 2008-207253 discloses a press brake inwhich the position of a finger of an operator is calculated from animage picked up by a CCD camera to compute a distance between the fingerand a ram, and if the distance is too short, operation speed of the ramis limited.

SUMMARY OF THE INVENTION

Japanese Patent Laying-Open No. 2008-207253 describes a configuration ofcalculating the distance from positional coordinates of the finger of ahand of the operator to a dangerous point, and if it is determined thatthe finger interferes with the ram, controlling the operation speed.

In order to identify the positional coordinates of the finger of thehand, calculate the distance to the dangerous point, and determinewhether or not the distance is within a predetermined distance, however,the process may be complicated.

The present disclosure has been made in view of the aforementionedproblem, and an object of the present disclosure is to provide acontroller capable of appropriately limiting operation speed of aforming machine in a simple manner, the forming machine including thecontroller, and a control method for controlling operation of theforming machine.

According to one embodiment, a controller controls operation of aforming machine capable of forming a workpiece. The controller includes:an object determination unit configured to determine an object otherthan the workpiece and the forming machine based on image data sensed bya sensor; a setting unit configured to set a plurality of determinationareas based on a bolster shape of the forming machine included in theimage data; a detection unit configured to detect entry of the objectinto each of the plurality of determination areas set by the settingunit; and a control unit configured to limit operation speed of theforming machine based on the determination area in which the entry ofthe object has been detected by the detection unit.

According to the above disclosure, the plurality of determination areasare set based on the bolster shape, and the operation speed of theforming machine is limited based on the determination area in which theentry of the object has been detected, thus allowing for a simpleprocess without the need to calculate the distance and the like.

Preferably, the setting unit is configured to set the plurality ofdetermination areas by varying a magnification of a size of the bolstershape of the forming machine.

According to the above disclosure, the plurality of determination areasare set by varying the magnification of the size of the bolster shape.Accordingly, the plurality of determination areas can be simply setwithout the need to set them by manual input or the like for eachforming machine.

Preferably, the bolster shape is a rectangular shape.

According to the above disclosure, since the bolster shape is arectangular shape, the plurality of determination areas are also set tohave the same shape as a machining area. Thus, the entry of the objectfrom various directions can be readily detected.

Preferably, the controller further includes a notification unitconfigured to make a notification of information based on thedetermination area in which the entry of the object has been detected bythe detection unit.

According to the above disclosure, a notification of entry of the objectcan be made appropriately owing to the additional provision of thenotification unit, thereby improving safety.

Preferably, the controller further includes an acquisition unitconfigured to acquire, from the sensor which outputs the image data fordetermining a distance in a height direction by sensing a predeterminedarea including a machining area of the forming machine, first image datanot including an image of the workpiece and an operator of the formingmachine, and second image data representing a current state of thepredetermined area during operation of the forming machine, as the imagedata. The object determination unit is configured to calculatedifference data indicating a difference between the first image data andthe second image data, and to determine an area of the operator in thepredetermined area based on the difference data.

According to the above disclosure, the area of the operator can bedistinguished using the image data obtained from the sensor whichoutputs image data for determining a distance in the height direction.This image data is less likely to be influenced by the surroundingenvironment than image data obtained by a CCD camera or the like. Thus,the area of the operator can be determined with high accuracy.Accordingly, the actual position of the operator can be reflected moreaccurately in the control of the operation speed of the forming machine.

Preferably, the object determination unit is further configured todetermine an area of the workpiece based on the difference data.

According to the above disclosure, the controller can distinguishbetween the workpiece and the operator. Accordingly, it is possible tocontrol the operation speed in consideration of the position of theworkpiece as well.

Preferably, the workpiece has a flat worked surface. The objectdetermination unit is configured to determine a flat area of theworkpiece as the determination of the area of the workpiece.

According to the above disclosure, a workpiece having a flat workedsurface is constant (horizontal) in the height direction during normalforming operation, and thus can be more readily distinguished than anon-flat worked surface. Accordingly, the area of the workpiece can bedistinguished with higher accuracy.

Preferably, the object determination unit includes a feature valuecalculation unit configured to divide a difference image based on thedifference data into a plurality of cells, and to calculate a HOG(Histogram of Oriented Gradients) feature value in the difference datafor each of the cells, and a similarity calculation unit configured tocalculate similarity between the HOG feature value and a feature valueof a shape of the workpiece for each of the cells. The objectdetermination unit is configured to determine the area of the operatorand the area of the workpiece based on the calculated similarity.

According to the above disclosure, the area of the workpiece and thearea of the operator can be determined by using the feature value of theshape of the workpiece.

Preferably, the object determination unit includes a feature valuecalculation unit configured to divide a difference image based on thedifference data into a plurality of cells, and to calculate a normalvector of an edge portion in the difference data for each of the cells,and a similarity calculation unit configured to calculate similaritybetween the normal vector and a vector representing a feature of a shapeof the workpiece for each of the cells. The object determination unit isconfigured to determine the area of the operator and the area of theworkpiece based on the calculated similarity.

According to the above disclosure, the area of the workpiece and thearea of the operator can be determined by using the vector representingthe feature of the shape of the workpiece.

Preferably, the object determination unit is configured to determinethat an area including a prescribed proportion or more of the cells inwhich the similarity is less than a reference value is the area of theoperator.

According to the above disclosure, the area of the operator can bedetermined based on the similarity calculated by the similaritycalculation unit.

Preferably, the object determination unit is configured to determinethat an area including a prescribed proportion or more of the cells inwhich the similarity is equal to or greater than a reference value isthe area of the workpiece.

According to the above disclosure, the area of the workpiece can bedetermined based on the similarity calculated by the similaritycalculation unit.

Preferably, the object determination unit is further configured todetermine an inclined area inclined at a prescribed angle based on thedifference data. The control unit is configured to limit the operationspeed when the inclined area is equal to or larger than a predeterminedsize.

When forming a workpiece having a flat worked surface, machiningaccuracy decreases unless the worked surface is placed horizontally.According to the above disclosure, if the inclined area is equal to orlarger than the predetermined size, it can be determined that the workedsurface is not placed horizontally, so that decrease in machiningaccuracy can be prevented by limiting the operation speed.

Preferably, the control unit is configured to stop a forming processwhen the inclined area is equal to or larger than the predeterminedsize.

According to the above disclosure, the forming process can be preventedfrom being performed when the worked surface is not horizontally placed.

According to another embodiment, a forming machine is capable of forminga workpiece. The forming machine includes: a body having a machiningarea where the workpiece is machined; a controller for controllingoperation of the forming machine; and a sensor for sensing apredetermined area including the machining area of the forming machine.The controller includes an object determination unit configured todetermine an object other than the workpiece and the forming machinebased on image data sensed by the sensor, a setting unit configured toset a plurality of determination areas based on a bolster shape of theforming machine included in the image data, a detection unit configuredto detect entry of the object into each of the plurality ofdetermination areas set by the setting unit, and a control unitconfigured to limit operation speed of the forming machine based on thedetermination area in which the entry of the object has been detected bythe detection unit.

According to the above disclosure, the plurality of determination areasare set based on the bolster shape, and the operation speed of theforming machine is limited based on the determination area in which theentry of the object has been detected, thus allowing for a simpleprocess without the need to calculate the distance and the like.

Preferably, the sensor is mounted on the body above the machining area.

According to the above disclosure, the predetermined area including themachining area can be sensed.

Preferably, the forming machine is a press machine.

According to the above disclosure, in the press machine, it is possibleto control the operation speed (press speed) while reflecting the actualposition of the operator more accurately.

According to yet another embodiment, a method for controlling a formingmachine is for controlling operation of a forming machine capable offorming a workpiece. The method for controlling a forming machineincludes the steps of: sensing a predetermined area including amachining area of the forming machine; determining an object other thanthe workpiece and the forming machine based on sensed image data;setting a plurality of determination areas based on a bolster shape ofthe forming machine included in the image data; detecting entry of theobject into each of the plurality of set determination areas; andlimiting operation speed of the forming machine based on thedetermination area in which the entry of the object has been detected.

According to the above disclosure, the plurality of determination areasare set based on the bolster shape, and the operation speed of theforming machine is limited based on the determination area in which theentry of the object has been detected, thus allowing for a simpleprocess without the need to calculate the distance and the like.

The foregoing and other objects, features, aspects and advantages of thepresent disclosure will become more apparent from the following detaileddescription of the present disclosure when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating the configuration of a press system.

FIG. 2 is a diagram representing a state in which an operator isperforming pressing operation within a work area.

FIG. 3 is a schematic diagram representing a background image.

FIG. 4 is a schematic diagram representing an example of a current stateimage.

FIG. 5 is a schematic diagram representing a difference image based ondifference data.

FIG. 6 is a diagram representing determined areas of the operator and ofa short size plate.

FIG. 7 is a functional block diagram illustrating a functionalconfiguration of an information processor and a press controller.

FIG. 8 is a diagram representing a background image based on backgroundimage data acquired from a sensor.

FIG. 9 is a diagram representing a current state image based on currentstate image data acquired from the sensor.

FIG. 10 is a diagram representing a difference image based on differencedata.

FIG. 11 is a diagram representing the difference image based on thedifference data after noise has been removed.

FIG. 12 is a diagram illustrating a method of calculating a HOG featurevalue.

FIG. 13 is a diagram representing an example histogram (HOG featurevalue) of a cell C_(i,j).

FIG. 14 is a diagram illustrating blocks and a normalization process.

FIG. 15 is a diagram visualizing the HOG feature values after thenormalization.

FIGS. 16A and 16B are diagrams representing reference vectors.

FIG. 17 is a diagram representing an image generated based on calculatedsimilarity.

FIG. 18 is a sequence chart illustrating a process flow in the presssystem.

FIG. 19 is a flowchart illustrating a process flow in the informationprocessor.

FIG. 20 is a diagram representing a typical hardware configuration ofthe information processor.

FIG. 21 is a diagram representing a state immediately before theoperator starts the pressing operation within the work area.

FIG. 22 is a diagram illustrating a functional configuration of a systemcontroller.

FIG. 23 is a diagram illustrating setting of a plurality ofdetermination areas.

FIG. 24 is a flow diagram illustrating a process flow in anotherinformation processor.

FIG. 25 is a flow diagram illustrating a subroutine of a detectionsignal outputting process.

FIG. 26 is a diagram illustrating an operation speed limitation tableincluded in a speed control unit.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description, the same components are designated by thesame signs. Their names and functions are also identical. Thus, detaileddescription thereof will not be repeated.

In this embodiment, a press machine will be described as an exampleforming machine. In addition, a member having a flat worked surface willbe described as an example workpiece to be pressed by the press machine.In particular, a short size plate will be described as an exampleworkpiece.

It is to be noted that the forming machine is not limited to a pressmachine, but may be another machine such as a press brake. In addition,the workpiece does not need to have a flat worked surface. It is onlyrequired that at least each workpiece to be machined have a certainshape.

A. Overall Configuration

FIG. 1 is a diagram illustrating the configuration of a press system 1.

As shown in FIG. 1, press system 1 includes a press machine 10, a sensor20, an information processor 30, and an input/output terminal 40.Information processor 30 is connected so as to be able to communicatewith sensor 20 and input/output terminal 40. Input/output terminal 40 isfurther connected so as to be able to communicate with press machine 10.

Press machine 10 includes a body frame 11, a bed 12, a bolster 13, aslide 14, a control panel 15, and a press controller 16.

Slide 14 is supported on a substantially central portion of body frame11 such that slide 14 can move up and down. Bolster 13 mounted on bed 12is disposed below slide 14. Control panel 15 is provided at the front ofbody frame 11. Press controller 16 connected to control panel 15 isprovided on the side of body frame 11.

A not-shown upper die is mounted on the lower surface of slide 14. Anot-shown lower die is mounted on the upper surface of bolster 13. Aprescribed workpiece corresponding to a die formed of the upper andlower dies is positioned on the lower die, and the upper die is moveddown with slide 14, to perform pressing.

Control panel 15 is for inputting various types of data required tocontrol press machine 10, and has switches and a numeric keypad throughwhich the data is input, as well as a display for displaying a settingscreen and data output from press machine 10.

Control panel 15 may include a device for receiving data from anexternal storage medium such as an IC card having preset data storedtherein, or a communication device to transmit/receive data wirelesslyor via communication lines.

It is to be noted that the above configuration of press machine 10 isexemplary and is not particularly limiting.

Press controller 16 of press machine 10 is a device to control theentire press machine 10. Press controller 16 is connected to controlpanel 15 and input/output terminal 40. Press controller 16 is configuredto include a computer device which is mainly formed of a CPU, ahigh-speed numerical operation processor, a memory and the like, andwhich performs arithmetic and logical operations of input data inaccordance with a predetermined procedure, and an input/output interfacewhich inputs/outputs a command current.

The memory of press controller 16 is configured to include anappropriate storage medium such as a ROM or RAM. This memory stores aprogram that allows press controller 16 to implement various functions.This memory is also used as a work area where various types ofarithmetic processing are performed.

Sensor 20 is a depth sensor. Sensor 20 is mounted on body frame 11 abovea machining area of press machine 10.

Sensor 20 transmits image data for determining a distance in a heightdirection to information processor 30 through a communication cable, bysensing a predetermined area including the machining area (hereinafteralso referred to as a “work area”). The image data output from sensor 20will be described later.

Information processor 30 acquires the image data from sensor 20.Information processor 30 performs various types of arithmetic processingbased on the image data acquired from the sensor. For example,information processor 30 calculates a HOG (Histogram of OrientedGradients) feature value. Information processor 30 also transmits asignal in accordance with a result of the processing to press controller16 of press machine 10.

The specific contents of the processing in information processor 30 anda hardware configuration of information processor 30 will be describedlater.

FIG. 2 is a diagram representing a state in which an operator isperforming pressing operation within the work area.

As shown in FIG. 2, an operator 90 moves a short size plate 80 as workto the machining area of press machine 10 while grasping short sizeplate 80. Operator 90 also places short size plate 80 on a lower die 17,with a flat worked surface of short size plate 80 facing an upper die18. Slide 14 moves down in this state, causing short size plate 80 to bepressed by the dies.

In the state of FIG. 2, operator 90 and short size plate 80 are presentin the work area, and therefore, operator 90 and short size plate 80 arealso sensed by sensor 20.

Although the above description refers to an example configuration inwhich press system 1 has information processor 30 separately from presscontroller 16, this is not limiting. Press controller 16 may beconfigured so as to perform various types of arithmetic processing ininformation processor 30. In such a configuration, press system 1 doesnot need to include information processor 30 and the input/outputterminal.

B. Overview of Processing

An overview of processing in press system 1 is described. Specifically,an overview of arithmetic processing in information processor 30 and anoverview of operation of press machine 10 based on the arithmetic resultwill be described.

(b1. Arithmetic Processing in Information Processor 30)

Information processor 30 acquires image data representing a backgroundimage of the work area (hereinafter also referred to as “backgroundimage data”) from sensor 20 in advance. Specifically, before thepressing is started, information processor 30 acquires image data notincluding an image of short size plate 80 and operator 90 of pressmachine 10 from sensor 20.

FIG. 3 is a schematic diagram representing the background image. Asshown in FIG. 3, the background image includes an image of press machine10, an image of the machining area, and an image of a floor surface ofworking space in which press machine 10 has been installed.

After acquiring the background image data, at least for a period of timeduring which press machine 10 is operating (typically, slide 14 ismoving up and down), information processor 30 acquires image data of thework area at prescribed timing (typically in a prescribed cycle)(hereinafter also referred to as “current state image data”) from sensor20. For example, in one aspect, information processor 30 acquires thecurrent state image data including images of short size plate 80 andoperator 90 from sensor 20 in a prescribed cycle. An image based on thecurrent state image data will be hereinafter also referred to as a“current state image.”

It is to be noted that the acquisition of the image data from sensor 20may be based on an acquisition request from information processor 30.Alternatively, sensor 20 may be configured to transmit the image data toinformation processor 30 without an acquisition request from informationprocessor 30.

FIG. 4 is a schematic diagram representing an example of the currentstate image. As shown in FIG. 4, in one aspect, the current state imageincludes an image of press machine 10, an image of the machining area,an image of the floor surface of the working space, an image of operator90, and an image of short size plate 80.

Information processor 30 calculates difference data indicating adifference between the current state image data and the background imagedata. Typically, information processor 30 calculates the difference dataeach time the current state image data is acquired from sensor 20.Specifically, information processor 30 calculates the difference data bysubtracting the background image data (pixel value) from the currentstate image data (pixel value) for each pixel of sensor 20.

It is to be noted that information processor 30 does not need tocalculate the difference data each time the current state image data isacquired from sensor 20. A cycle of the acquisition of the current stateimage data does not need to match a cycle of the calculation of thedifference data. For example, after the image data is acquired multipletimes, difference data between the last acquired current state imagedata of the multiple acquisitions and the background image data may becalculated.

FIG. 5 is a schematic diagram representing a difference image based onthe difference data. In the difference data, pixel values of an areaother than the areas of operator 90 and short size plate 80 (area aroundan object that has entered the work area) are offset. Accordingly, asshown in FIG. 5, information processor 30 can distinguish between theareas of operator 90 and the short size plate and the other area in thedifference data.

Since slide 14 moves up and down, the position of slide 14 when thebackground image data is acquired may be different from the position ofslide 14 when the current state image data is acquired. That is, data ofa portion of slide 14 may remain in the difference data. However, anarea (region) where slide 14 can be present in the difference data canbe identified in advance, so that information processor 30 candistinguish between the areas of operator 90 and short size plate 80 andthe other area.

Information processor 30 further determines the area of operator 90 andthe area of short size plate 80 based on the difference data.Specifically, information processor 30 distinguishes between the area ofoperator 90 and the area of short size plate 80 through a process ofcalculating similarity using a HOG feature value.

FIG. 6 is a diagram representing the determined areas of operator 90 andof short size plate 80. As shown in FIG. 6, the position of operator 90and the position of short size plate 80 can be identified through thearithmetic processing by information processor 30.

Information processor 30 transmits a signal in accordance with a resultof the determination to press controller 16 of press machine 10 throughinput/output terminal 40. The signal in accordance with thedetermination result may be positional data on the operator andpositional data on the short size plate themselves, or may be aseparation distance between the operator and the machining area.Alternatively, the signal in accordance with the determination resultmay be a signal indicative of, when the separation distance between theoperator and the machining area is partitioned into a plurality ofsections (areas), which section the signal belongs to (areadetermination signal).

It is to be noted that “sensor 20,” “background image data” and “currentstate image data” are examples of a “sensor,” “first image data” and“second image data” of the present disclosure, respectively.

(b2. Operation of Press Machine 10 Based on Arithmetic Result)

Press machine 10 controls operation speed based on the signal inaccordance with the determination result received from informationprocessor 30. For example, press machine 10 reduces a press speed(specifically, a movement speed of slide 14) when operator 90 movescloser to the machining area, and increases the press speed whenoperator 90 moves away from the machining area. As a result, saferpressing operation than heretofore possible can be implemented. Thecontrol of the operation speed will be described later in detail.

C. Functional Configuration

FIG. 7 is a functional block diagram illustrating a functionalconfiguration of information processor 30 and press controller 16. It isto be noted that a “system controller 50” configured to includeinformation processor 30 and press controller 16 is an example of a“controller” of the present disclosure.

Information processor 30 includes an acquisition unit 31 and adetermination unit 32. Determination unit 32 includes a HOG processingunit 321 and a similarity calculation unit 322. Press controller 16includes a speed control unit 161.

Acquisition unit 31 acquires background image data and current stateimage data from sensor 20. Acquisition unit 31 acquires the currentstate image data in a cyclic fashion. Acquisition unit 31 transmits theacquired background image data and current state image data todetermination unit 32.

Determination unit 32 calculates difference data between the backgroundimage data and the current state image data, and determines the area ofoperator 90 and the area of short size plate 80 based on the differencedata. Specifically, determination unit 32 performs this areadetermination process using HOG processing unit 321 and similaritycalculation unit 322.

HOG processing unit 321 divides the difference image into a plurality ofcells. Typically, HOG processing unit 321 divides the difference imageinto a plurality of unit areas. Furthermore, HOG processing unit 321calculates a HOG feature value in the difference data for each cell. HOGprocessing unit 321 transmits the calculated HOG feature value tosimilarity calculation unit 322.

Similarity calculation unit 322 calculates, for each cell, similaritybetween the calculated HOG feature value and a previously stored featurevalue of the shape of short size plate 80.

Based on the calculated similarity, determination unit 32 determines thearea of operator 90 and the area of short size plate 80. Determinationunit 32 transmits a signal in accordance with a result of thedetermination to press controller 16 through input/output terminal 40.

Press controller 16 receives the signal in accordance with thedetermination result from information processor 30. Speed control unit161 of press controller 16 controls the operation speed of press machine10 based on the signal in accordance with the determination result.Specifically, press controller 16 controls the movement speed of slide14 by generating a control signal for controlling the movement speed ofslide 14.

It is to be noted that “acquisition unit 31,” “setting unit 323,”“detection unit 324” and “HOG processing unit 321 and similaritycalculation unit 322” are examples of an “acquisition unit,” a “settingunit,” a “detection unit” and an “object determination unit” of thepresent disclosure, respectively.

D. Specific Examples of Processing

Described below is a specific example of processing performed in systemcontroller 50 (FIG. 7) based on the actually obtained image data.

(d1. Acquisition of Difference Image)

FIG. 8 is a diagram representing a background image based on backgroundimage data acquired from sensor 20. Specifically, FIG. 8 is a diagramrepresenting a background image displayed on a display of informationprocessor 30. As shown in FIG. 8, the background image is typicallydisplayed as a gray scale image. The background image has shadesaccording to the distance in the height direction from sensor 20. Thebackground image is darker in color as the distance from sensor 20decreases, and is lighter in color as the distance from sensor 20increases.

FIG. 9 is a diagram representing a current state image based on currentstate image data acquired from sensor 20. Specifically, FIG. 9 is adiagram representing a current state image displayed on the display ofinformation processor 30. As with the background image, the currentstate image is typically displayed as a gray scale image.

As shown in FIG. 9, the current state image is different from thebackground image shown in FIG. 8 in that it includes the image ofoperator 90 and the image of short size plate 80.

FIG. 10 is a diagram representing a difference image based on differencedata. Specifically, FIG. 10 is a diagram of a difference image betweenthe background image shown in FIG. 8 and the current state image shownin FIG. 9, which is displayed on the display of information processor30.

As shown in FIG. 10, it can be seen in the difference image that thearea of operator 90 and the area of short size plate 80 are generallywhite in color. Moreover, as can be seen from the difference image, thedifference data includes noise. Thus, information processor 30 performsa process of removing the noise from the difference data. This noiseremoval process is performed, for example, in determination unit 32.

FIG. 11 is a diagram representing the difference image based on thedifference data after the noise has been removed. As shown in FIG. 11,in the difference image after the noise removal, the difference betweenthe areas of operator 90 and short size plate 80 and the other area isclarified.

(d2. HOG Processing)

Described below is a process performed in HOG processing unit 321 ofinformation processor 30 (FIG. 7). The HOG processing is performed onthe difference data after the noise removal.

FIG. 12 is a diagram illustrating a method of calculating a HOG featurevalue. As shown in FIG. 12, HOG processing unit 321 divides thedifference image into a plurality of cells C_(i,j) (i and j are naturalnumbers equal to or greater than one). Each cell C_(i,j) is typically asquare, which consists of 36 pixels including six vertical pixels andsix horizontal pixels, for example.

HOG processing unit 321 calculates a gradient vector in each pixel.Specifically, HOG processing unit 321 calculates an orientation in whichthe brightness varies (gradient orientation: 0° to 180°) and brightnessdifference (gradient intensity). In FIG. 12, the gradient vector in eachpixel of a cell C_(1,1) is schematically represented in a visualizedmanner. It is to be noted that only the gradient orientation may becalculated, without calculation of the gradient intensity.

HOG processing unit 321 further divides an angle of between 0° and 180°into nine orientations in increments of from 0° to 20°. HOG processingunit 321 creates a histogram, for each cell C_(i,j), which has ahorizontal axis representing nine angles (0°, 20°, 40°, . . . , 140°,160°) and a vertical axis representing a sum (frequency) of gradientintensities of these angles.

FIG. 13 is a diagram representing an example histogram (HOG featurevalue) of a single cell C_(i,j). As shown in FIG. 13, the frequency isdetermined for each of the nine angles. In the following description, aHOG feature value F_(i,j) in each cell C_(i,j) is represented as anine-dimensional vector as expressed in the following equation (1), forexample:F _(i,j) ={f ₁ ,f ₂ ,f ₃ ,f ₄ ,f ₅ ,f ₆ ,f ₇ ,f ₈ ,f ₉}  (1)

It is to be noted that f₁, f₂, f₃, . . . , f₉ correspond to 0°, 20°,40°, . . . , 160°, respectively.

HOG processing unit 321 performs a normalization process for each blockconsisting of a plurality of cells. Each block consists of nine cellsincluding three vertical cells and three horizontal cells, for example.

FIG. 14 is a diagram illustrating the blocks and the normalizationprocess. As shown in FIG. 14, a block B_(i,j) consists of a cellC_(i,j), a cell C_(i,j+1), a cell C_(i,j+2), a cell C_(i+1,j), a cellC_(j+1,j+1), a cell C_(i+1,j+2), a cell C_(i+2,j), a cell C_(i+2,j+1),and a cell C_(i+2,j+2).

FIG. 14 illustrates a block B_(1,1), a block B_(1,8), and a blockB_(6,1). In particular, for block B_(1,1) and block B_(1,8), the cellsforming each block and HOG feature value F_(i,j) in each cell areillustrated.

HOG processing unit 321 normalizes cell C_(i+1,j+1) at the center ofeach block B_(i,j) using the HOG feature values of eight cells aroundthis cell C_(i+1,j+1) (the other cells in this block). Looking at blockB_(1,1), for example, a central cell C_(2,2) is normalized using the HOGfeature values of eight cells around cell C_(2,2) (specifically, cellsC_(1,1), C_(1,2), C_(1,3), C_(2,1), C_(2,3), C_(3,1), C_(3,2), C_(3,3)).

Specifically, HOG processing unit 321 performs the normalization processfor each block using the following equation (2), and calculates a HOGfeature value v after the normalization of each cell C_(i,j):

$\begin{matrix}{v_{{i + 1},{j + 1}} = \frac{F_{{i + 1},{j + 1}}}{\sqrt{{V}_{k}^{2} + ɛ^{2}}}} & (2)\end{matrix}$

In the equation (2), V represents a vector defined by the HOG featurevalues of nine cells included in block B_(i,j) (F_(i,j), F_(i,j+1),F_(i,j+2), F_(i+1,j), F_(i+1,j+1), F_(i+1,j+2), F_(i+2,j+1),F_(j+2,j+2)). An L1 norm is represented when a subscript k of the normis 1, an L2 norm is represented when k is 2, and an L∞ norm isrepresented when k is ∞. In this embodiment, ε has a value of 1.

FIG. 15 is a diagram visualizing the HOG feature values after thenormalization. In FIG. 15, the HOG feature value of a single cell in anarea P at the worked surface of short size plate 80, and the HOG featurevalue of a single cell in an area Q at an end portion (edge) of shortsize plate 80 are displayed in an enlarged manner.

The area of short size plate 80 is formed by a linear contour and a flatsurface. On the other hand, the area of operator 90 is formed by acurvilinear contour and a rounded surface. Thus, the HOG feature valueswith different tendencies will be obtained from the area of short sizeplate 80 and the area of operator 90. For example, the HOG feature valueobtained in the area of operator 90 indicates a tendency different fromthose of the two HOG feature values displayed in an enlarged manner inFIG. 15.

Determination unit 32 distinguishes between the area of operator 90 andthe area of short size plate 80 by utilizing such difference in tendencybetween the HOG feature values. Specifically, determination unit 32distinguishes between the area of operator 90 and the area of short sizeplate 80 based on the similarity calculated by similarity calculationunit 322.

Since there is no object present in the surrounding area other than theareas of operator 90 and short size plate 80, a HOG feature value uniqueto this surrounding area is obtained. Thus, determination unit 32 canexclude the surrounding area when distinguishing between the area ofoperator 90 and the area of short size plate 80.

(d3. Calculation of Similarity)

Described below is the process of calculating the similarity bysimilarity calculation unit 322.

Similarity calculation unit 322 calculates, for each cell C_(i,j), thesimilarity between the HOG feature value (specifically, the HOG featurevalue after the normalization) and the feature value of the shape ofshort size plate 80. The feature value of the shape of short size plate80 is determined in advance by performing the following process.

Information processor 30 calculates an average value of feature vectorsat ten locations of the flat worked surface (horizontally placed workedsurface) of short size plate 80. Similarity calculation unit 322utilizes the calculated average value (feature vector) as a firstreference vector I_(ref1). Information processor 30 also calculates anaverage value of feature vectors at a plurality locations (for example,ten locations) of an edge portion of short size plate 80. Similaritycalculation unit 322 utilizes the average value (feature vector) at theedge portion as a second reference vector I_(ref2). It is to be notedthat the two reference vectors will be expressed as “I_(ref)” when nodistinction is made between them.

FIGS. 16A and 16B are diagrams representing reference vectors I_(ref).FIG. 16A is a diagram representing an example of first reference vectorI_(ref1). FIG. 16B is a diagram representing an example of secondreference vector I_(ref2). Referring to FIGS. 16A and 16B, thehorizontal axis represents nine inclination angles (0°, 20°, 40°, . . ., 140°, 160°), while the vertical axis represents intensitycorresponding to the aforementioned frequency (intensity ofinclination).

Similarity calculation unit 322 utilizes reference vectors I_(ref) suchas shown in FIGS. 16A and 16B as the feature value of the shape of shortsize plate 80, to calculate the similarity with the HOG feature value.Typically, similarity calculation unit 322 calculates the similarityusing cosine similarity. Specifically, similarity calculation unit 322calculates the similarity using the following equation (3):

$\begin{matrix}{{\cos\left( {\overset{\rightarrow}{I_{ref}},\overset{\rightarrow}{v_{ij}}} \right)} = \frac{\overset{\rightarrow}{I_{ref}} \cdot \overset{\rightarrow}{v_{ij}}}{{\overset{\rightarrow}{I_{ref}}}\;{\overset{\rightarrow}{v_{ij}}}}} & (3)\end{matrix}$

FIG. 17 is a diagram representing an image generated based on thecalculated similarity. As shown in FIG. 17, an area that has beendetermined to have similarity equal to or greater than a reference valuein the difference image, and an area that has been determined to havesimilarity less than the reference value in the difference image can bedistinguished from each other.

Based on the calculated similarity, determination unit 32 determines thearea of operator 90 and the area of short size plate 80. Specifically,determination unit 32 determines that an area including a prescribedproportion or more of the cells in which the calculated similarity isless than the reference value is the area of operator 90. Determinationunit 32 also determines that an area including a prescribed proportionor more of the cells in which the calculated similarity is equal to orgreater than the reference value is the area of short size plate 80. Thereference value and the prescribed proportion are defined in advance.

Determination unit 32 transmits a signal in accordance with a result ofthe determination to press controller 16 through input/output terminal40, as described above. Press controller 16 controls the operation speedof press machine 10 based on the signal in accordance with thedetermination result, as described above.

E. Control Structure

FIG. 18 is a sequence chart illustrating a process flow in press system1. As shown in FIG. 18, in a sequence SQ11, sensor 20 transmitsbackground image data to information processor 30. Information processor30 stores the background image data in the memory. In a sequence SQ12,sensor 20 transmits current state image data. The transmission of thecurrent state image data is typically repeated in a prescribed cycle, asdescribed above.

In a sequence SQ21, information processor 30 calculates difference databetween the background image data and the current state image data.Information processor 30 calculates the difference data each time thecurrent state image data is acquired from sensor 20. In a sequence SQ22,information processor 30 determines the area of operator 90 and the areaof short size plate 80 based on the difference data. In a sequence SQ23,information processor 30 transmits a signal in accordance with thedetermination result to press controller 16 of press machine 10.

In a sequence SQ31, press controller 16 generates a control signal forcontrolling the movement speed of slide 14 based on the signal inaccordance with the determination result. In a sequence SQ32, presscontroller 16 transmits the generated control signal to a drive circuitthat operates slide 14.

Subsequently, a process similar to the series of processes indicated bysequences SQ12, SQ21, SQ22, SQ23, SQ31 and SQ32 is repeated. When thenext current state image data is received from sensor 20 in a sequenceSQ13, in a sequence SQ24, information processor 30 calculates differencedata, as in sequence SQ21. Moreover, in a sequence SQ25, informationprocessor 30 determines the area of operator 90 and the area of shortsize plate 80 based on the difference data calculated in sequence SQ24,as in sequence SQ22. In a sequence SQ26, information processor 30transmits a signal in accordance with the determination result to presscontroller 16, as in sequence SQ23.

FIG. 19 is a flowchart illustrating a process flow in informationprocessor 30. As shown in FIG. 19, in step S1, information processor 30acquires background image data representing the background image of thework area from sensor 20. In step S2, information processor 30 acquirescurrent state image data, which has been obtained by picking up an imageof the current state of the work area, from sensor 20.

In step S3, information processor 30 calculates difference data betweenthe background image data and the current state image data bysubtracting the background image data from the current state image data.In step S4, information processor 30 performs HOG processing on thecalculated difference data. In step S5, information processor 30calculates, for each cell C_(i,j), similarity between the HOG featurevalue and the aforementioned two reference vectors I_(ref) representingthe feature of short size plate 80.

In step S6, information processor 30 determines the area of operator 90and the area of short size plate 80 based on the calculated similarity.In step S7, information processor 30 transmits a signal in accordancewith the determination result to press controller 16.

F. Hardware Configuration

FIG. 20 is a diagram representing a typical hardware configuration ofinformation processor 30. Referring to FIG. 20, information processor 30includes a processor 101 such as a CPU, a memory 102, a display 103, anoperation key 104, communication interfaces 105, 106, and a power supplycircuit 107.

Processor 101 controls the entire operation of information processor 30.

Memory 102 stores an operating system, a program for implementing thedetermination process and the like described above, and various types ofdata.

Display 103 displays various types of information based on aninstruction from processor 101. For example, display 103 displaysvarious types of images such as the background image, the current stateimage, and the difference image.

Communication interface 105 is a communication processing unit forcommunicating with sensor 20. Communication interface 105 receives imagedata output from sensor 20. Communication interface 105 transmits thereceived image data to processor 101.

Communication interface 106 is a communication processing unit forcommunicating with input/output terminal 40. Processor 101 transmits asignal in accordance with the determination result to input/outputterminal 40 through communication interface 106.

Power supply circuit 107 is a circuit for supplying electric power froma power supply drawn into the working space to each block withininformation processor 30 and to not-shown circuits.

It is to be noted that acquisition unit 31 shown in FIG. 7 correspondsto communication interface 105. Determination unit 32 shown in FIG. 7 isimplemented by processor 101 executing the program stored in memory 102.

G. Summary of Embodiment

(1) As discussed above, press system 1 can distinguish the area ofoperator 90 using the image data obtained from sensor 20 which outputsimage data for determining a distance in the height direction. Thisimage data is less likely to be influenced by the surroundingenvironment than image data obtained by a CCD camera or the like. Thus,press system 1 can determine the area of operator 90 with high accuracy.Accordingly, press system 1 can reflect the actual position of operator90 more accurately in the control of the operation speed of pressmachine 10.

(2) Moreover, press system 1 further determines the area of short sizeplate 80 based on the difference data. Thus, press system 1 candistinguish between the workpiece and the operator. Accordingly, presssystem 1 can control the operation speed in consideration of theposition of short size plate 80 as well.

(3) A workpiece having a flat worked surface like short size plate 80 isconstant (horizontal) in the height direction during normal pressingoperation, and thus can be more readily distinguished than a non-flatworked surface. Accordingly, press system 1 can distinguish the area ofshort size plate 80 with higher accuracy.

(4) Moreover, press system 1 can determine the area of short size plate80 and the area of operator 90 by using the feature value of the shapeof short size plate 80 (reference vectors I_(ref) representing thefeature). Specifically, press system 1 can determine the area of shortsize plate 80 and the area of operator 90 based on the similaritycalculated by similarity calculation unit 322.

(5) Being mounted on body frame 11 above the machining area, sensor 20can sense the work area including the machining area.

H. Variations

(h1. Determination of Inclination)

In the above embodiment, when the worked surface of short size plate 80is horizontally placed, the area of short size plate 80 can bedetermined by utilizing the aforementioned two reference vectorsI_(ref). Described below is a process for the case where operator 90brings short size plate 80 closer to the machining area, with the workedsurface of short size plate 80 being inclined from the horizontal plane.

FIG. 21 is a diagram representing a state immediately before theoperator starts the pressing operation within the work area. As shown inFIG. 21, if operator 90 brings short size plate 80 into the machiningarea, with a worked surface 80 a of short size plate 80 being inclinedfrom the horizontal plane, a pressing process may not be able to beperformed with high accuracy.

In addition, if short size plate 80 is inclined as shown in FIG. 21, itis likely that information processor 30 will not be able to determinethe area of short size plate 80 by means of the aforementioned tworeference vectors I_(ref). Thus, determination unit 32 of informationprocessor 30 determines the inclined area inclined at a prescribedangle, together with the area of operator 90, based on the differencedata. Determination unit 32 transmits a signal based on a result of thedetermination to speed control unit 161 of press controller 16.

When the inclined area inclined at a prescribed angle is equal to orlarger than a predetermined size, speed control unit 161 limits a pressspeed of press machine 10. For example, speed control unit 161 causesthe pressing process (operation of slide 14) to stop.

By limiting the operation speed in this manner, decrease in machiningaccuracy can be prevented, thereby maintaining the pressing process withhigh accuracy. In addition, safer pressing operation than heretoforepossible can be implemented. Particularly if the configuration is suchthat the pressing process is stopped when the inclined area is equal toor larger than the predetermined size as described above, a formingprocess can be prevented from being performed when the worked surface isnot horizontally placed.

(h2. Use of Normal Vector)

Although the above embodiment refers to an example configuration inwhich the HOG feature value of a cell is calculated by HOG processingunit 321, this is not limiting. Any configuration capable of calculatingthe feature value of a cell can be employed without being particularlylimited. For example, the configuration can be as follows.

First, instead of calculating the HOG feature value, a normal vector ofan edge portion in the difference data is calculated for each cellC_(i,j). Moreover, similarity calculation unit 322 calculates, for eachC_(i,j), similarity between the calculated normal vector and referencevectors I_(ref) representing the feature of short size plate 80. Then,determination unit 32 determines the area of operator 90 and the area ofshort size plate 80 based on the calculated similarity.

Such configuration can provide the same effect as that of the embodimentdescribed above.

I. Mode of Limiting Operation Speed of Press Machine 10

Next, a mode of setting determination areas based on image data, andappropriately limiting the operation speed of press machine 10 basedthereon is described.

FIG. 22 is a diagram illustrating a functional configuration of a systemcontroller 50# based on the embodiment.

Referring to FIG. 22, system controller 50# is different from systemcontroller 50 of FIG. 7 in that information processor 30 has beenreplaced by an information processor 30# and press controller 16 hasbeen replaced by a press controller 16#.

Information processor 30# is different from information processor 30 inthat determination unit 32 has been replaced by a determination unit32#.

Determination unit 32# is different from determination unit 32 in thatit further includes a setting unit 323 and a detection unit 324.

Press controller 16# is different from press controller 16 in that itfurther includes a notification unit 162. The configuration is otherwisethe same as that described with reference to FIG. 7, and thus detaileddescription thereof will not be repeated.

Determination unit 32# includes HOG processing unit 321 and similaritycalculation unit 322, and as described above, calculates the differencedata between the background image data and the current state image dataacquired by acquisition unit 31.

Then, as described above, the area of operator 90 and the area of shortsize plate 80 are distinguished by HOG processing unit 321 andsimilarity calculation unit 322. Thus, the areas of short size plate 80which is a workpiece and of operator 90 which is an object other thanpress machine 10 are distinguished.

Setting unit 323 sets a plurality of determination areas based on theimage data acquired by acquisition unit 31. Specifically, setting unit323 extracts the shape of bolster 13 of press machine 10 included in theacquired background image data. Setting unit 323 sets the plurality ofdetermination areas based on the extracted bolster shape.

The plurality of determination areas are used so as to determine whetheror not an object (for example, the area of operator 90) determined bythe above HOG processing unit 321 and similarity calculation unit 322has entered each of the determination areas.

Detection unit 324 detects entry of the object (the area of operator 90)into each of the plurality of determination areas that have been set bysetting unit 323. Detection unit 324 outputs a signal in accordance withthe detection to press controller 16#.

Press controller 16# performs prescribed operation based on the signalin accordance with the detection that has been output from informationprocessor 30#. Specifically, based on the signal in accordance with thedetection, speed control unit 161 outputs a control signal for limitingthe press speed to press machine 10. Press machine 10 limits the pressspeed in accordance with the control signal.

Notification unit 162 makes a notification of information based on thesignal in accordance with the detection. Specifically, notification unit162 emits alarm sound or displays information on a not-shown displaybased on the signal in accordance with the detection.

FIG. 23 is a diagram illustrating the setting of the plurality ofdetermination areas based on the embodiment.

Referring to FIG. 23, a plurality of determination areas A1 to A8 areillustrated in this example.

Determination area A1 is an area equivalent to bolster 13 in shape.Bolster 13 is shown to have a rectangular shape in this example. It isto be noted that the corners of bolster 13 do not need to form a rightangle as the rectangular shape, but the corners may also be rounded. Itis to be noted that determination area A1 does not need to completelymatch bolster 13 in shape, but is only required to have substantiallythe same shape.

Bolster 13 in this example can be extracted from image data obtained bysensing the machining area by means of sensor 20 mounted on the upperportion of body frame 11. Specifically, the shape of the bolster can beextracted by pattern matching. Although this example describesextracting the shape of a portion of bolster 13 included in the imagedata, the shape of the entire bolster 13 may be extracted.

Setting unit 323 extracts the bolster shape based on the image data andsets determination area A1, and sets an additional plurality ofdetermination areas. Specifically, setting unit 323 sets determinationareas A2 to A8 by varying a magnification of the size of the bolstershape (determination area A1).

Determination area A1 has the smallest area, and then the determinationareas increase in area in ascending order.

The plurality of determination areas are illustrated with varyingmagnifications, with the lower sides of the four sides of thedetermination areas being aligned in the same direction. This mode ofsetting the determination areas is exemplary and not particularlylimited. For example, the plurality of determination areas may be setwith varying magnifications, with the barycenter of determination areaA1 as a reference position.

Since the determination areas are set in accordance with the bolstershape included in the machining area of the image data, thedetermination areas can be simply set without the need to set them basedon manual input or the like for each press machine 10.

Although this example describes setting eight determination areas, thenumber of determination areas is not particularly limited to eight. Theset determination areas may be any number equal to or greater than two.

FIG. 24 is a flow diagram illustrating a process flow in informationprocessor 30# based on the embodiment.

Referring to FIG. 24, information processor 30# acquires image data(step S12). Specifically, acquisition unit 31 acquires background imagedata from sensor 20.

Then, information processor 30# extracts a bolster shape (step S14).Specifically, setting unit 323 extracts the bolster shape based on thebackground image data acquired by acquisition unit 31.

Then, information processor 30# sets determination areas (step S16).Specifically, setting unit 323 sets a plurality of determination areasas described with reference to FIG. 23 based on the extracted bolstershape.

Then, information processor 30# performs a detection signal outputtingprocess (step S18). The detection signal outputting process will bedescribed later in detail.

Then, information processor 30# determines whether or not the processinghas ended (step S20). Specifically, it can be determined that theprocessing has ended when the process of press machine 10 has ended.

When it is determined that the processing has ended in step S20 (YES instep S20), information processor 30# causes the process flow to end(END).

When it is determined that the processing has not ended in step S20 (NOin step S20), on the other hand, information processor 30# causes theprocess flow to return to step S18, where the detection signaloutputting process is performed.

FIG. 25 is a flow diagram illustrating a subroutine of the detectionsignal outputting process.

Referring to FIG. 25, information processor 30# determines whether ornot there is an object (step S22). As described above, it is determinedwhether or not there is an object by HOG processing unit 321 andsimilarity calculation unit 322. Specifically, difference data betweenthe background image data and the current state image data acquired byacquisition unit 31 is calculated, to distinguish the area of operator90 and the area of short size plate 80 in accordance with the modedescribed with reference to FIG. 19. Thus, it is determined whether ornot there is an object (the area of operator 90) other than short sizeplate 80 which is a workpiece and press machine 10.

When it is determined that there is an object in step S22 (YES in stepS22), information processor 30# detects entry of the object (step S24).

Detection unit 324 detects entry of the distinguished object into eachof the plurality of determination areas. When it is determined that theobject is in a plurality of determination areas, detection unit 324preferentially detects a determination area of the smallest number(determination area of a small area). For example, when the object isdetected in determination areas A6 to A8, it is determined that theobject has been detected in determination area A6 (that the object hasentered determination area A6).

Then, information processor 30# outputs a detection signal based on thedetermination area (step S26). Detection unit 324 outputs a detectionsignal based on the determination area based on the detection result.For example, when it is determined that the object has been detected indetermination area A6, detection unit 324 may output a signal indicatingthat the object has been detected in determination area A6.Alternatively, detection unit 324 may output information concerning anarea number.

Then, information processor 30# causes the detection signal outputtingprocess to end (RETURN).

When it is determined that there is no object in step S22 (NO in stepS22), information processor 30# causes the detection signal outputtingprocess to end (RETURN).

FIG. 26 is a diagram illustrating an operation speed limitation tableincluded in speed control unit 161.

Referring to FIG. 26, the operation speed limitation table is a tablethat associates a detected area and speed.

Speed control unit 161 outputs a control signal relating to the speedlimit to press machine 10, in accordance with the detection signal basedon the determination area from information processor 30#.

Specifically, when the object is detected in determination area A1, acontrol signal indicating a stop is output. When the object is detectedin determination area A2, a control signal indicating the setting of thespeed to 10% is output. In accordance with this control signal, a targetspeed set in press machine 10 (speed of slide 14 and the like) islimited to a speed of a prescribed percentage. When the object isdetected in determination area A3, a control signal indicating thesetting of the speed to 20% is output. When the object is detected indetermination area A4, a control signal indicating the setting of thespeed to 30% is output. When the object is detected in determinationarea A5, a control signal indicating the setting of the speed to 40% isoutput. When the object is detected in determination area A6, a controlsignal indicating the setting of the speed to 60% is output. When theobject is detected in determination area A7, a control signal indicatingthe setting of the speed to 80% is output. When the object is detectedin determination area A8, the speed is 100%. Thus, the operation speedis not limited. In this case, a control signal indicating the setting ofthe speed to 100% may be output, or the control signal for limiting thespeed may not be output.

For example, when a signal indicating that the object has been detectedin determination area A6 is received from information processor 30#,speed control unit 161 outputs the control signal indicating the settingof the speed to 60%. The speed of press machine 10 is thus appropriatelylimited, thereby ensuring the safety of operator 90, for example.

In this example, the plurality of determination areas are set inaccordance with the bolster shape included in the machining area, andthe speed of press machine 10 is limited based on the determination areain which the entry of the object has been detected.

Therefore, the entry of the object into the machining area from variousdirections can be detected, thus allowing for appropriate control of thespeed of press machine 10.

In addition, press controller 16# includes notification unit 162.Notification unit 162 performs a prescribed notification process inresponse to the detection signal based on the determination area basedon the detection result.

Specifically, the volume of a notification signal can be changeddepending on the determination area. For example, the volume of alarmsound can be increased as the distance from determination area A1decreases. Alternatively, instead of sound, a warning may be indicatedby displaying a message. For example, the size of characters of thedisplayed message may be changed, or a display process such as blinkingmay be performed, as the distance from determination area A1 decreases.

Moreover, although the above description describes distinguishing thearea of short size plate 80 from the area of operator 90 to determinethe area of operator 90 to be an object, when the inclined area inclinedat a prescribed angle is equal to or larger than the predetermined size,the portion of this area may be determined to be an object, as wasdescribed with respect to the determination of inclination of the workedsurface of short size plate 80 above.

Then, by limiting the operation speed based on the determination result,decrease in machining accuracy can be prevented, thereby maintaining thepressing process with high accuracy. In addition, safer pressingoperation than heretofore possible can be implemented. If theconfiguration is such that the pressing process is stopped when theinclined area is equal to or larger than the predetermined size asdescribed above, a forming process can be prevented from being performedwhen the worked surface is not horizontally placed.

Although the embodiments of the present invention have been described,it should be understood that the embodiments disclosed herein areillustrative and non-restrictive in every respect. The scope of thepresent invention is defined by the terms of the claims, and is intendedto include any modifications within the scope and meaning equivalent tothe terms of the claims.

What is claimed is:
 1. A controller comprising: a communicationinterface accepting an image data sensed by a sensor, and a processorconnected to the communication interface, for controlling operation of aforming machine capable of forming a workpiece, the processor performingthe method comprising: determining an object other than the workpieceand the forming machine based on the image data sensed by the sensor;extracting a bolster shape of the forming machine included in the imagedata; setting at least three determination areas based on the bolstershape of the forming machine included in the image data, wherein eachset determination area of the at least three determination areas has adifferent area size based on a size of the bolster shape, and wherein adifferent speed limitation based on the area size of the setdetermination area is associated with each set determination area of theat least three determination areas; detecting entry of the object intoone or more of the set determination areas of the at least three setdetermination areas; and limiting an operation speed of the formingmachine by the speed limitation associated with the set determinationarea based on the speed limitation associated with an innermost setdetermination area of the one or more set determination areas in whichthe entry of the object has been detected.
 2. The controller accordingto claim 1, wherein setting the at least three determination areas basedon the bolstered shape of the forming machine including in the imagedata includes: setting the at least three determination areas by varyinga magnification of the size of the bolster shape of the forming machine,wherein the area size of a determination area of the at least threedetermination areas increases as the magnification of the size of thebolster shape increases.
 3. The controller according to claim 1, whereinthe bolster shape is a rectangular shape.
 4. The controller according toclaim 1, wherein the processor performing the method further comprising:making a notification of information based on the one or more setdetermination areas in which the entry of the object has been detected.5. The controller according to claim 1, wherein the processor performingthe method further comprising: acquiring, from the sensor which outputsthe image data for determining a distance in a height direction bysensing a predetermined area including a machining area of the formingmachine, i) first image data not including an image of the workpiece andan operator of the forming machine, and ii) second image datarepresenting a current state of the predetermined area during operationof the forming machine, as the image data; calculating difference dataindicating a difference between the first image data and the secondimage data; and determining an area of the operator in the predeterminedarea based on the difference data.
 6. The controller according to claim5, wherein the processor performing the method further comprising:determining an area of the workpiece based on the difference data. 7.The controller according to claim 6, wherein the workpiece has a flatworked surface, and wherein the processor performing the method furthercomprising: determining a flat area of the workpiece as thedetermination of the area of the workpiece.
 8. The controller accordingto claim 6, wherein the processor performing the method furthercomprising: dividing a difference image based on the difference datainto a plurality of cells; calculating a HOG (Histogram of OrientedGradients) feature value in the difference data for each of the cells;and calculating similarity between the HOG feature value and a featurevalue of a shape of the workpiece for each of the cells, whereindetermining the area of the operator and determining the area of theworkpiece is based on the calculated similarity.
 9. The controlleraccording to claim 6, wherein the processor performing the methodfurther comprising: dividing a difference image based on the differencedata into a plurality of cells; calculating a normal vector of an edgeportion in the difference data for each of the cells; and calculatingsimilarity between the normal vector and a vector representing a featureof a shape of the workpiece for each of the cells, wherein determiningthe area of the operator and determining the area of the workpiece isbased on the calculated similarity.
 10. The controller according toclaim 8, wherein the processor performing the method further comprising:determining that an area including a prescribed proportion or more ofthe cells in which the similarity is less than a reference value is thearea of the operator.
 11. The controller according to claim 8, whereinthe wherein the processor performing the method further comprising:determining that an area including a prescribed proportion or more ofthe cells in which the similarity is equal to or greater than areference value is the area of the workpiece.
 12. The controlleraccording to claim 7, wherein the wherein the processor performing themethod further comprising: determining an inclined area inclined at aprescribed angle based on the difference data; and limiting theoperation speed when the inclined area is equal to or larger than apredetermined size.
 13. A forming machine capable of forming aworkpiece, comprising: a body having a machining area where theworkpiece is machined; a controller for controlling operation of theforming machine; and a sensor for sensing a predetermined area includingthe machining area of the forming machine, the controller including:determining an object other than the workpiece and the forming machinebased on image data sensed by a sensor, setting at least threedetermination areas based on a bolster shape of the forming machineincluded in the image data, wherein each set determination area has adifferent area size based on a size of the bolster shape, and wherein adifferent speed limitation based on the area size of the setdetermination area is associated with each set determination area of theat least three determination areas, detecting entry of the object intoone or more the set determination areas of the at least three setdetermination areas; and limiting an operation speed of the formingmachine by the speed limitation associated with the set determinationarea based on the speed limitation associated with an innermost setdetermination area of the one or more set determination areas in whichthe entry of the object has been detected.
 14. The forming machineaccording to claim 13, wherein the sensor is mounted on the body abovethe machining area.
 15. A method for controlling a forming machinecapable of forming a workpiece, comprising the steps of: sensing apredetermined area including a machining area of the forming machine;determining an object other than the workpiece and the forming machinebased on sensed image data; setting at least three determination areasbased on a bolster shape of the forming machine included in the imagedata, wherein each set determination area has a different area sizebased on a size of the bolster shape, and wherein a different speedlimitation based on the area size of the set determination area isassociated with each set determination area of the at least threedetermination areas; detecting entry of the object into one or more theset determination areas of the at least three set determination areas;and limiting an operation speed of the forming machine by the speedlimitation associated with the set determination area based on the speedlimitation associated with an innermost set determination area of theone or more set determination areas in which the entry of the object hasbeen detected.
 16. A controller comprising: a communication interfaceaccepting an image data sensed by a sensor, and a processor connected tothe communication interface, for controlling operation of a formingmachine capable of forming a workpiece, the processor performing themethod comprising: acquiring, from the sensor which outputs the imagedata for determining a distance in a height direction by sensing apredetermined area including a machining area of the forming machine, i)first image data not including an image of the workpiece and an operatorof the forming machine, and ii) second image data representing a currentstate of the predetermined area during operation of the forming machine,as the image data, wherein the workpiece has a flat worked surface;calculating difference data indicating a difference between the firstimage data and the second image data; and determining an area of theoperator in the predetermined area based on the difference data;determining an area of the workpiece based on the difference data;determining a flat area of the workpiece as the determination of thearea of the workpiece; determining an inclined area inclined at aprescribed angle based on the difference data; determining an objectother than the workpiece and the forming machine based on the image datasensed by the sensor; extracting a bolster shape of the forming machineincluded in the image data; setting a plurality of determination areasbased on the bolster shape of the forming machine included in the imagedata; detecting entry of the object into one or more of the setdetermination areas of the plurality of set determination areas;limiting an operation speed of the forming machine by a speed limitationassociated with a set determination area of the plurality of setdetermination areas based on the one or more set determination areas inwhich the entry of the object has been detected; and limiting theoperation speed when the inclined area is equal to or larger than apredetermined size.